DETN8R previously posted:
"Swapping the gears in the T-Case doesn't seem too daunting. I've rebuilt the np231 t-case in my old TJ before. (Granted Adam was helping me and did most of the work).
I don't have the space to store a complete other vehicle to do the swap. I feel like I could probably modify the engine harness myself if I had to. I certainly think I can add the vss switch to the cluster myself.
Does the 1.6 swap require a new radiator?
Great looking setup Bloodbane! I really need to get out wheeling with some other Samurai's."
Some guys get by with the stock Samurai radiator. I went with the genesis aluminum. 100.00 and bolt in stock location. I have never ran over the 190 (normal) mark. Even crawling around in the middle of summer.
as far as the T-case goes, for the 6.5:1 gears you have to clean the inner case up (grind some out). The gears will bind on the case otherwise. I went with a total rebuilt case from Low Range (LROR) in mine. Parts were almost as much (new bearings and seals, upgraded shafts and gears all together), and I got everything bolt in this way. I traded my stock case to Myron (ZOR) for the wire harness mods. If you deal with him, he will walk you through installing everything if you run into trouble.